Different types of maintenance culture for industrial purposes

As maintenance is essential in the industrial world, different types must be examined to ensure positive result achieved after the implementation. The different types of maintenance are used to increase the longevity or uptime of assets and utility of organizational facilities. In a previous article, where I briefly examined maintenance as a routine recurring work required to keep a facility (plant, building, structure, ground facility, utility system and other real property) in such condition that may be continuously used, at its original or designed capacity and efficiency for its intended purpose.

Maintenance types

Maintenance is based on an organization’s budget, amount of resources, maintenance goals, level of combined experience etc. It is now left to choose one or more maintenance types to be used. it is rare for an organization to implement a single type of maintenance, though assets are not created equal. For an asset that worth $100,000 and above will have conditional monitoring sensor attached to it for predictive maintenance. And for an asset that $5,000 will be exposed to preventive or corrective maintenance.

Organizations need to understand the various types of maintenance so as to know the one to implement. They must also know the type they are currently using to know if the maintenance goal is attained.

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Today we’ll be looking deep into the different maintenance culture that must be established in an organization.

Types of Maintenance Culture:

Below are the different types of maintenance culture:

Preventive Maintenance:

Preventive maintenance is regular routine inspecting with the intention of noticing minor issues and fixing them before major ones develop. Ideally, the machine or equipment is in good condition which means nothing breaks down. This type of maintenance is abbreviated as PM. The main purpose of the preventive maintenance is for the equipment to make it from one planned service to the next planned service. This will help to avoid failures caused by fatigue, wear, or neglect.

Preventive maintenance refers to the care and servicing by personnel for the purpose of maintaining equipment in satisfactory operating condition. This provides systematic inspection, detection, correction of incipient failures either before they occur or before they develop into major defects.

Preventive maintenance also includes tests, measurements, adjustments, parts replacement, and cleaning, performed in order to prevent faults from occurring.

Finally, it is said to be work carried out on equipment significantly to avoid breakdown or malfunction. It is a regular and routine action taken on equipment in order to prevent its breakdown,

The main objective of preventive maintenance includes the enhancement of the capital equipment productive life, reduce critical equipment breakdown, and minimize production loss due to equipment failures.

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Types of maintenance

Preventive Maintenance may also be seen as the following:

  • Planned Maintenance
  • Scheduled Maintenance
  • Planned Preventive Maintenance
  • Breakdown Maintenance, and
  • Maintenance Strategy

Planned Maintenance:

The planned preventive maintenance is more commonly referred to as simply planned maintenance (PM) or scheduled maintenance. It is any variety of scheduled maintenance to an object or item of equipment. This maintenance is performed by a competent and suitable agent as a scheduled service visit, whose work is to ensure the item of equipment is working perfectly. And also avoid any unplanned breakdown and downtime.

Planned maintenance is preplanned, and can be date-based, depending on the equipment running hours. There are parts that have scheduled maintenance at fixed intervals, usually due to wear-out. This is sometimes known as time-change interval or TCI items.

Predictive Maintenance:

Predictive maintenance techniques are designed to determine the condition of in-service equipment. The purpose is to estimate when maintenance should be carried out. This technique assures cost savings over routine or time-based preventive maintenance because tasks are performed at a proper time.

The main purpose of preventive maintenance is to warrant convenient scheduling of corrective maintenance and to prevent unexpected equipment failures.

Condition-Based Maintenance:

Condition-based maintenance CBM is described shortly as maintenance when the need arises. In some field where the acronym CBM is described as condition-based monitoring rather than maintenance. It is considered one section or practice inside the broader and newer predictive maintenance field, where new Al technologies and connectivity abilities are put to action.

The CBM maintenance is performed after one or more indicators show that equipment is going to fail or the equipment performance is bad. This maintenance tries to preserve the correct equipment at the right time.

Some benefits and limitations of CBM include:

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Below are the advantages of CBM over planned maintenance:

  • Improved system reliability
  • Decrease maintenance costs
  • Decreased number of maintenance operations causes a reduction of human error influences

While the disadvantages include:

  • Increased numbers of parts (the CBM installation itself) that need maintenance and checking.
  • High installation costs, for minor equipment items often more than the value of the equipment.
  • Unpredictable maintenance periods cause costs to be divided unequally.

Due to the high cost of CBM, it’s not used for less important parts of machinery despite the advantages of its offers. However, this maintenance is applicable where increased reliability and safety is required.

Corrective Maintenance:

The corrective type of maintenance is carried out after the complete breakdown or malfunction of equipment. It tends to be expensive because there are multiple damages apart from the worn parts. Serious repair and replacement costs and loss of revenues due to the downtime during overhaul can be meaningful.

Corrective maintenance also includes the rebuilding and resurfacing of equipment and infrastructure damaged by erosion and corrosion. Some conventional process like welding and metal flame spraying, as well as engineered solutions with thermoset polymeric material, will also be performed.

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Predictive Maintenance:

The predictive maintenance in more advance in sensing and computing technology. It uses the maintenance strategy to monitor key parameters within a system or machine. It uses the data with the analyzed historical trends to continuously evaluate the system health and also predict a breakdown before it happens. The predictive type of maintenance tends to be more efficient due to the fact that more up-to-date data is collected about the machine issues.

That’s for this article “Various types of Maintenance Culture for Industries.” I hope the knowledge is attained, if so, kindly comment, share, and recommend this site to other technical students. Thanks!

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